A float collar tool for running a casing string assembly into a wellbore includes a non-fragmenting rupture disc that temporarily isolates light fluid trapped in a lower portion of the casing string from heavier fluid in the upper portion of the casing string, thereby reducing the horizontal weight of the casing string by an amount sufficient to overcome a drag force. After the casing string is landed at a final location in the wellbore, the rupture disc is burst by increasing fluid pressure in the upper portion of the casing string. The increased pressure activates a piston that then moves the burst rupture disc into a protective region of the tool so that the inside diameter of the casing string is substantially restored.
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1. A tool for running a casing string in a wellbore, comprising:
a cylindrical housing having a sidewall having an inside diameter that defines a fluid passageway extending between first and second ends of the housing, the first and second ends configured to connect the housing within a casing string;
an isolation barrier disposed within the cylindrical housing and having a closed state and an open state, the isolation barrier having a cylindrical wall that is movable along the sidewall of the cylindrical housing and a barrier wall, wherein, in the closed state, the cylindrical wall is disposed at a first location along the sidewall and the barrier wall blocks the inside diameter to fluidly isolate an upper portion of the passageway from a lower portion of the passageway, and wherein, in the open state, the barrier wall allows for fluid communication through the fluid passageway; and
a protective region within the cylindrical housing to contain the isolation barrier when in the open state so that the isolation barrier does not restrict the inside diameter,
wherein, after the isolation barrier is placed in the open state, the cylindrical wall of the isolation barrier is moved in an axial direction from the first location along the sidewall to a second location within the protective region so that the isolation barrier is contained within the protective region.
5. A method for running a casing string assembly into a wellbore, comprising:
connecting a float collar tool within a casing string assembly, the float collar tool comprising:
a cylindrical housing having a fluid passageway extending between an upper end and a lower end;
an isolation barrier having a cylindrical wall disposed at a first location along the fluid passageway and a barrier wall temporarily disposed across a diameter of the fluid passageway to create a buoyant chamber in which a light fluid is trapped in a lower portion of the casing string assembly; and
a protective region formed in the cylindrical housing to store the isolation barrier after the casing string is landed at a final location in the wellbore;
providing a fluid in an upper portion of the casing string assembly that is heavier than the light fluid trapped in the lower portion of the casing string assembly;
landing the casing string assembly at the final location in the borehole;
increasing fluid pressure in the upper portion of the casing string assembly to disrupt the barrier wall of the isolation barrier and provide fluid communication between the upper and lower portions; and
moving the cylindrical wall in an axial direction along the passageway from the first location to a second location within the protective region, thereby moving the disrupted barrier wall into the protective region to restore the diameter of the fluid passageway.
12. A casing string assembly for completing a wellbore, comprising:
a lower casing string portion;
an upper casing string portion; and
a float collar tool connected between the lower and upper casing string portions, the float collar tool including:
a cylindrical housing having a fluid passageway that extends between an upper end and a lower end of the housing, wherein the upper end of the housing is connected to the upper casing string portion and the lower end of the housing is connected to the lower casing string portion;
a barrier disposed within the fluid passageway during run-in of the casing string assembly in the wellbore, the barrier comprising a cylindrical wall that is moveable along the fluid passageway and a barrier wall that temporarily blocks the fluid passageway, wherein the cylindrical wall is positioned at a first location along the fluid passageway during run-in and is moved in an axial direction from the first location to a second location after landing the casing string assembly at a final location in the wellbore and opening the barrier wall to fluid flow through the fluid passageway; and
a protective region formed within the cylindrical housing to store the barrier when the cylindrical wall is moved to the second location; and
a buoyant chamber containing a light fluid, the buoyant chamber extending between the barrier and a fluid blocking device disposed in the lower casing string portion,
wherein, during run-in of the casing string assembly in the wellbore, the barrier isolates the light fluid in the buoyant chamber from a heavier fluid in the upper casing string portion.
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This application claims the benefit of U.S. Provisional Patent Application No. 62/398,198, entitled “Floatation Collar for Use in Floating Casing to Depth by Reducing Casing Drag,” filed on Sep. 22, 2016, which is hereby expressly incorporated herein by, reference in its entirety.
The present disclosure relates generally to downhole equipment for hydrocarbon wells. More particularly, the present disclosure pertains to a method and apparatus for floating casing to depth in a wellbore.
Hydrocarbon fluids such as oil and natural gas are obtained from a subterranean geologic formation, referred to as a reservoir, by drilling a well that penetrates the hydrocarbon-bearing formation. Once a wellbore is drilled, a casing is then lowered and set in place.
In many wells, it can be difficult to run the casing to great depths because friction between the casing and the wellbore during run-in often results in a substantial amount of drag. This is particularly true in horizontal and/or deviated wells, where, in some cases, the drag on the casing can exceed the available weight of the casing in the vertical section of the wellbore that would otherwise tend to progress the casing further along. If there is insufficient weight in the vertical portion of the wellbore, it can be difficult or impossible to overcome the drag in the wellbore, thus limiting the depth to which the casing can be run or preventing completion of a horizontal or deviated well.
The following introduces a selection of concepts in a simplified form in order to provide a foundational understanding of some aspects of the present disclosure. The following is not an extensive overview of the disclosure, and is not intended to identify key or critical elements of the disclosure or to delineate the scope of the disclosure. The following merely presents some of the concepts of the disclosure as a prelude to the more detailed description provided thereafter.
According to an embodiment, a tool for running a casing string in a wellbore is disclosed. The tool includes a cylindrical housing having an inside diameter that defines a fluid passageway extending between first and second ends of the housing, the first and second ends configured to connect the housing within a casing string. The tool also includes an isolation barrier disposed within the cylindrical housing and having closed and open second states, wherein, in the closed state, the isolation barrier seals the inside diameter to fluidly isolate an upper portion of the passageway from a lower portion of the passageway, and wherein, in the open state, the isolation barrier allows for fluid communication through the fluid passageway. A protective region is formed in the cylindrical housing to contain the isolation barrier when in the open state so that the isolation barrier does not restrict the inside diameter.
According to another embodiment a method for running a casing string assembly into a wellbore includes connecting a float collar tool within the casing string assembly. The float collar tool comprises a cylindrical housing having a fluid passageway extending between an upper end and a lower end, an isolation barrier temporarily disposed across a diameter of the fluid passageway to create a buoyancy chamber in which a light fluid is trapped in a lower portion of the casing string assembly; and a protective region formed in the cylindrical housing to store the isolation barrier after the casing string is landed at a final location in the wellbore. The method further includes providing a fluid in an upper portion of the casing string assembly that is heavier than the light fluid trapped in the lower portion of the casing string assembly, landing the casing string assembly at the final location in the borehole, and then increasing fluid pressure in the upper portion of the casing string assembly to disrupt the isolation barrier and provide fluid communication between the upper and lower portions. The disrupted isolation barrier is then moved into the protective region to restore the diameter of the fluid passageway.
In another embodiment, a casing string assembly for completing a wellbore includes a lower casing string portion, an upper casing string portion, and a float collar tool connected between the lower and upper casing string portions. The float collar tool includes a cylindrical housing having a fluid passageway that extends between an upper end and a lower end of the housing, wherein the upper end of the housing is connected to the upper casing string portion and the lower end of the housing is connected to the lower casing string portion. The tool further includes a barrier disposed within the fluid passageway during run-in of the casing string assembly in the wellbore, and a protective region formed within the cylindrical housing to store the barrier after landing the casing string assembly at a final location in the wellbore. The assembly also has a sealed buoyancy chamber that contains a light fluid and that extends between the barrier and a sealing device disposed in the lower casing string portion. During run-in of the casing string assembly in the wellbore, the barrier isolates the light fluid in the buoyancy chamber from a heavier fluid in the upper casing string portion.
Certain embodiments of the invention are described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying drawings illustrate only the various implementations described herein and are not meant to limit the scope of various technologies described herein. Various embodiments of the current invention are shown and described in the accompanying drawings of which:
The headings provided herein are for convenience only and do not necessarily affect the scope or meaning of what is claimed in the present disclosure.
Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numbers are used to identify like elements illustrated in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same.
Various examples and embodiments of the present disclosure will now be described. The following description provides specific details for a thorough understanding and enabling description of these examples. One of ordinary skill in the relevant art will understand, however, that one or more embodiments described herein may be practiced without many of these details. Likewise, one skilled in the relevant art will also understand that one or more embodiments of the present disclosure can include other features and/or functions not described in detail herein. Additionally, some well-known structures or functions may not be shown or described in detail below, so as to avoid unnecessarily obscuring the relevant description.
Certain terms are used throughout the following description to refer to, particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.
In the following discussion, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. Any reference to up or down in the description is made for purposes of clarity, with “up”, “upper,” “upwardly”, or “upstream” meaning toward the surface of the borehole and with “down”, “lower”, “downwardly”, “downhole”, or “downstream” meaning toward the terminal end of the borehole, regardless of the borehole orientation.
Systems and techniques for lowering a casing or a liner (either referred to herein as casing) to a desired depth or location in a borehole that penetrates a hydrocarbon reservoir are well known. However, because friction between the casing and the borehole can create drag, running the casing to great depths or over extended horizontal distances can be challenging. In boreholes that are non-vertical, such as horizontal or deviated wellbores, the drag can present a large obstacle to completing the well. Various techniques have been developed to overcome this drag so that greater vertical well depths and horizontal wells can be achieved. For instance, techniques to lighten or “float” the casing have been used to extend the depth of or to complete the well. For example, techniques are known in which the ends of a casing string portion are plugged and are filled with a low density, miscible fluid to provide a buoyant force. However, after the plugged portion is placed in the wellbore, the plug must be drilled out, and the low density miscible fluid is forced out into the wellbore.
According to other known techniques for floating casing, a rupture disc assembly is provided where, after the casing is installed in the wellbore, the rupture disc can be ruptured by engagement with an impact surface of a tube. However, engagement with the impact surface shatters the disc, resulting in shattered disc fragments that remain in the wellbore. These fragments can damage the casing string or tools lowered within the string as fluid circulates within the wellbore. Moreover, the inside diameter of the casing may be restricted following the rupture of the disc, which can later prevent or impede conveyance of downhole tools within the restricted region of the casing string so that further operations, such as cementing, cannot be readily performed using conventional techniques.
Embodiments disclosed herein are directed to devices and methods to float a casing string in a wellbore in order to extend the depth or horizontal distance and that, when employed, do not introduce damaging debris or unduly restrict the inside diameter of the casing.
Referring now to
The casing string assembly 100 also includes a fluid blocking device 132 located in a lower portion of the casing string 100, such as at or near the terminal end of the string 100. In embodiments, the blocking device 132 can be located one or more thousands of feet from the float collar tool 116. The blocking device 132 prevents drilling fluids or other wellbore fluids from entering the casing string assembly 100 as it is being run into the wellbore 100. As such, when the float collar tool 116 is added to the string 100 and is in its closed state, the blocking device 132 and collar 116 operate in conjunction to form a buoyant chamber 130 in the lower portion of the casing string assembly 100 in which a light fluid (e.g. air, gas or other lightweight fluid) is trapped, as will be further described below. In embodiments, the blocking device 132 can be a temporary plug that is removed after the casing 100 is positioned at the desired final location. Or, the device 132 can be a one-way float valve that prevents fluid from entering the casing string 100, but allows fluid to be pumped through the string 100 during circulation and/or cementing after the collar 116 has been converted to its open state.
Float collar 116 can be converted between an initial closed state (shown in
According to an embodiment, the float collar 116 is connected within the casing string 100 so as to maximize vertical weight on the casing string 100, while minimizing horizontal weight. To that end, in an embodiment, the isolation barrier 124 traps air and/or other low weight fluid in the lower tool portion 128 (and lower portion of the casing string 100) and isolates the lower portion 128 from heavier fluid in the upper portion 126 of the tool 116 (and the upper portion of the casing string 100 and wellbore 110). In operation, when the tool 116 is in the closed state, the isolation barrier 124 isolates the upper portion 126 of the fluid passageway (which is filled with a heavier fluid) from the buoyant chamber 130 in the passageway that extends between the barrier 124 and the fluid blocking device 132 (which contains a lighter weight fluid). As an example, heavier fluid in the upper portion 126 can be drilling mud, and the lighter weight fluid in the buoyant chamber 132 can be air, nitrogen, carbon dioxide, oil and/or other lightweight or miscible fluid. As will be appreciated by persons skilled in the art, this configuration reduces weight of the casing string 100 and consequently the drag and frictional force acting on the casing string 100 in accordance with Archimedes' Principle.
As further illustrated in
The installation of the casing string assembly 100 into a wellbore 110 and the operation of the tool 116 will next be described with reference to
In an embodiment, the casing string 100 is run into the wellbore 110 for a desired initial distance (block 152) using a conventional technique. The fluid blocking device 132 at the end of the string 100 prevents fluids in the wellbore 110 from entering the casing 100. Once the desired initial distance is reached, the float collar tool 116 is added to the casing string 100, e.g., by threadedly coupling the ends 120 and 122 of the tool 116 to casing string 100 subs (block 154). When the float collar tool 116 is added to the string 100, the isolation barrier 124 is in the closed state in which it blocks the internal passageway of the tool 116 and, thus, fluidly isolates the upper section 126 from the lower section 128. In the closed state, air, gas and/or other light weight fluid are trapped in the buoyant chamber 130. Heavier fluid, such as drilling mud, is then provided above the isolation barrier 124 to continue the run-in of string 100 in the wellbore 110 (block 156). In an embodiment, to prevent premature removal of the barrier 124, the rupture burst pressure of the rupture disc 127 is greater than the hydrostatic pressure of the heavier fluid during run-in of the casing string 100.
The distance that the casing string 100 is run before adding the float collar 116 depends on the configuration of the particular wellbore 110. In general, the float collar 116 is added at a location within the casing string 100 to create buoyancy so that the casing string 100 can be run in horizontal or deviated sections of the wellbore 110 without generating a drag force that is great enough to prevent the string 100 from reaching its final desired location. To that end, the float collar tool 116 is positioned at a location within the casing string 100 to assist in overcoming the drag forces on the casing string 100, thereby allowing, the casing string to be positioned at greater depths or extended to greater horizontal distances.
Once the casing string 100 has been run and landed at the final desired location in the wellbore 110, the isolation barrier 124 is transitioned to the open state in which fluid communication is provided between the upper section 126 of the passageway and the buoyant chamber 130 (block 158). In an embodiment, the barrier 124 is placed in the open state by pressuring the casing string 100 from the surface 112 (e.g., by applying fluid pressure through the casing 100) by a sufficient amount to burst the rupture disc 127. A person skilled in the art will understand that the isolation barrier 124 can be configured to have any suitable rupture pressure depending on the particular application in which the float collar tool 116 is employed.
According to an embodiment, the rupture disc 127 is a non-fragmenting type, so that it bursts but does not fragment into shards. Once the disc 127 bursts, the heavier fluid in the upper section 126 of the tool 116 mixes with the air and other low weight fluid in the buoyant chamber 130. Fluid flow through the casing string 100 following the burst may allow the trapped air and low weight fluid in the buoyant chamber 130 to rise to the surface and be vented outside the casing string 100.
Further, in the embodiment illustrated, as the heavier fluid replaces the air and the lighter fluid, the heavier fluid flows through fluid port 140 and increases the hydrostatic pressure in the piston chamber 138. Once a sufficient imbalance is achieved between the hydrostatic pressure in chamber 138 and pressure (e.g., atmospheric pressure) in the first chamber 134, the piston 136 shifts in the upward direction towards the upper end 120 of the tool 116. In other embodiments, the piston 136 can be hydraulically operated via appropriate hydraulic lines operated from the surface, as an example. In yet other embodiments, the slidable sleeve can be mechanically shifted so that it moves the barrier 124 into the protective region 144, such as by a spring or other resilient member.
In the embodiment shown in
In the embodiment shown in
For the purposes of promoting an understanding of the principles of the invention, reference has been made to the embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art. Descriptions of features or aspects within each embodiment should typically be considered as available for other similar features or aspects in other embodiments unless stated otherwise. The terminology used herein is for the purpose of describing the particular embodiments and is not intended to be limiting of exemplary embodiments of the invention.
The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. Numerous modifications and adaptations will be readily apparent to those of ordinary skill in this art without departing from the scope of the invention as defined by the following claims. Therefore, the scope of the invention is not confined by the detailed description of the invention but is defined by the following claims.
Williamson, Scott Earl, Dedman, Michael R.
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Sep 21 2017 | WILLIAMSON, SCOTT EARL | KLX INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 043665 | /0416 | |
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Sep 22 2017 | DEDMAN, MICHAEL R | KLX INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 043665 | /0416 | |
Jan 09 2018 | KLX, INC | KLX Energy Services LLC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 044588 | /0926 | |
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Nov 16 2018 | KLX Energy Services LLC | WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT | PATENT SECURITY AGREEMENT - NOTES | 048150 | /0474 |
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